Dry primary cell



2 sheets-snee*v I S. RUBEN DRY PRIMARY CELL @Earns/Mrap .SHEET cau/oss March I8, 1949.

Filed Dec. 9. 1942 57L SHEET 6019750 W/TH 572-51. sf/fr March s, 1949. s. RUBEN 2,463,565

DRY PRIMARY CELL Filed Dec. 9, 1942 2 Sheets-Sheet 2 mVENroR. 25a/hud fu @en UPF@ fczwam DRY PRBIABY CELL v samuel anun. New muelle, N. Y. Application December s, 1942, serial No. casse c einen. (ci. 13s-116) 1 This invention relates to methods of making dry primary cells.

An object of the invention is to improve dry cells.

high current capacity for a given Another object 4is to improve thelife of a pri- 5 marycell under adverse\conditions.

Other objects of the invention will be apparent from the description and claims.

The present application is a continuation part of my prior illed co-pending application, Serial Number 456,160, illed August 26, 1942, now abandoned.

In the drawings:

Figure 1 is a perspective view of a portion of a primary cell during assembly, portions of one electrode and of the spacers being cut away to better illustrate the order of the layers;

Figure 2 is a section through the completed primay cell;

Figure 27a is a section partly broken away 20 through primary cells of modied construction, arranged in a battery;

Figure 3 illustrates an electrode assembly of a modified construction.

Fig'ure 4 shows the parts for a disc type cell I arranged in the order of assembly;

Figure 5 is a cross section th-rough a completed disc cell;

Figure 6 illustrates va battery formed of securing together several cells in face-to-face contact; and Y Figure 7 shows, in section, a battery made of several cells enclosed in a cardboard tube.

The present invention contemplates a. primary cell for supplying current as a result ofelectrochemical action wherein the electrolyte is a solid crystalline material containing water of hydration. The invention is applicable to primary cells of various types using a variety of electrodes and acid, alkaline or salt electrolytes having ineluded water of hydration. The invention, in its prefer-red form, uses alkaline electrolytes, such as the alkali metal hydroxides containing water of hydration. l Y

Heretofore primary cells have been produced using alkaline electrolytes such as potassium and sodium hydroxide as liquid solutions. These have always required careful handling in order to prevent loss of the electrolyte. Moreover, such primary cells were subject to rapid deterioration at elevated temperatures due to accelerated attack.

on the electrodes by the electrolyte. Zinc is commonly used as one electrode in such cells and it is quite susceptible to attack by liquid alkaline solutions. I

- been formed either of porous carbon or of cupric volume of cell. However, when the 'cell is left on open circuit, trouble results due to some of the copper compound dissolving in the electrolyte and migrating to the zinc electrode where copper is deposited. setting up local electrochemical action and causing 'rapid dissolution of the zinc electrode. This action is `much accelerated when the temperature of thecell is increased. For this reason such cells haveheretofore not been found satisfactory where theywere required to be stored or left on \open circuit for any extended period of time and it Ahas been also necessary -to space the zinc 'and copper compound electrodes rather tar apart.

In the prior art in the so-called dry cells' the' electrolyte is aliquid but is prevented from running out of the cell by being absorbed in a porous solid such as paper, carbon, manganese dioxide or ilnely divided inert porous materials. I-Iowever, theelectrolyte remains as liquid when absorbed in these media. Its chemical and corrosive action at high temperatures, resulting in a deterioration of the cells, is not reduced. Electrolytes have also been immobilized by the addition of a gelatinlzing agent such as starch but gen- -erally this has not reducedthe chemical shelf action or deterioration at elevated temperatures.

I have found that alkaline dry cells can be produced which have a good open circuit life, even at elevated temperatures such as are encountered in the tropics, by using solid crystalline alkaline electrolytes and by closely spacing the cooperating electrodes so as to'rkeep the resistance of the -cells at a low value. .The solid electrolyte helps to prevent migration of copper compounds which would otherwise attack the zinc electrode and also, because of its solid nature, does not itself readily attack either the zinc or copper\oxide electrodes when the cell is on open circuit.

In order for the cells to be of general utility both at temperatures normally encountered in this country and also at elevated temperatures such as are encountered in the ltropics or in equipment where considerable heat is generated it is not only necessary that the'cells have good shelf '50 at the higher temperatures.

I have found that solid potassium hydroxide containingwater of hydration is an ideal lelectrolyte for meetingv these requirements; that it possessesa much lower specic resistivity in the solid crystalline form than the other solid alkali Depolarizing electrodes for such cells have Referring to the drawing whereinFigures 1 and 2 illustrate the construction of a dry cell of analice thenv laid on one side of the remaining unwound.

end of the steel strip and two other layers Il of regenerated sheet cellulose are placed on the opposite side oi' thesteel strip. A-strip of corrugated zinc foil I4 is then placed against the outside of one of the cellulose sheets and the entire assembly is Wound into a roll wherein the coated steel sheet is separated from the corrugated zinc foil by double layers of regenerated sheet cellulose. The regenerated cellulose separatorsmay be suillciently long to form a iinal turn on the outside of the roll.

v A depolarizing cupric oxide composition I5 is applied as a coating to steel4 sheet II prior to assembly. The composition may be formed by milling together 46 grams of a mixture of finely divided cupric oxide with8%y of graphite of extremely small particle size, such as 5 to 9 microns and 30 grams of a 10% solution of polymerizcd vinyl chloride in a solvent, such as an ether. The

resulting composition is applied (for example, by spraying or painting) to both surfaces of steel sheet I I after it has first been sand blasted. Sheet II may suitably be formed. of steel 2 mils thick. Where operation of the cell at low temperatures is not required, the graphite content may be substantially reduced and for some applications the graphite may be omitted. Generally, the percentage of' graphite will be from 0.1% to 10% by Weight of the cupric oxide.

A preferred thickness for the coat is about 2.75 mils on each side of the steel backing. After drying, the coating is baked at a temperature of 130 C. for several hours. The coated steel strip may then be rolled between steel rollers such as those used for rolling metal stock. This increases the density and conductivity of the coating, giving it a smooth uniform surface. The rolling is done at a relatively high temperature such as around 125. C.

In the prior art where a composite copperoxide carbon electrode has been used, the function of the carbon has been to lower the resistance of the electrode; whereas in the present cell, the micronized graphite serves primarily to prevent the insulating organic binder from insulating the cupric oxide particles from themselves and from the steel base electrode.

Another method of preparing a copper oxide electrode, Where cost is not a factor, is to oxidize a copper or copper plated foil, to provide a cupric oxide surface.

The zinc foil strip I 4 is preferably corrugated with about 16 corrugations to the inch, the corrugations being about 2 mils deep. A tab I6 of the can to prevent contact between the rod I0 i r l 4 and tab'IG is spot-welded to the can wall by a weld I9. A disc of insulating material which is not attacked by alkalies is placed in the bottom and the bottom of the can.

The electrolyte'is prepared by dissolving from 200 to 400 grams of C. P. potassium hydroxide (containing 13 to 14% water) in 100 milliliters of water, 300 grams of potassium hydroxide being the preferred quantity for 'normal commercial use. This produces solutions containing between 43 and water and"57 and 70% KOH, approximately; or preferably water and 65% KOH approximately. It is necessary to heat the water to about 120 C.v to dissolve all the hydroxide.

A The cell assembly which` has been produced in the manner above described is heated to about 100 C. and immersed at this temperature in the hot liquid electrolyte and a partial vacuum (such a hard solid 24 in which 40 stiff insulating material such as formed of a strip of heavier zinc is spot-welded at I1 to the outer end of the zinc electrode I4 to afford a means for securing the electrode to the container. Zinc i4 may suitably be of 2 or 3 mils in thickness. The regenerated cellulose sheetsmay each be 1 to 1.5 mils thick when dry and should preferably be free of plasticizer such as glycerine. The cellulose sheets are slightly wider than the electrodes to provide overlapping edges and to prevent short circuits at the edges of the roll. i

After the roll is wound as illustrated in Figure 1, it is inserted in a zinc can I8 as shown in Figure 2 'of the can I8,

as a reduction in pressure to 5 cm. of mercury) lis preferably applied to improve the impregnation of the space between the electrodes and the absorption of the electrolyte into the regenerated sheet cellulose spacers.

Some of the regenerated cellulose is attacked by the strong alkalibut the attack is insuiilcient to injure the spacer or reduce its effectiveness in the cell assembly. The spacer absorbs a large quantity of the electrolyte and in so doing swells to fill the available space between the electrodes provided by the corrugation of the zinc electrode. The filled cells are then removed from the electrolyte bath and allowed to cool. The electrolyte crystallizes when the cells have cooled to about C. and at room temperature the electrolyte is the assembly is imbedded, the melting point usually being above 60 C.

The can I8 has a slightly enwlarged portion at its open end providing a shoulder 2l. A disc 22 of Bakelite,I dielectine, or other sufliciently rigid material is covered on one side and around its edges with a sheet 23 of rubber. Neoprene or similar rubbery material which is resistant to the alkaline electrolyte and this assembly is pressed onto the top so as to rest against shoulder 2I after which the rim of the can is spun over the edge ofthe assembly to secure it in place and seal the cell. The disc 22 has a relatively large central aperture and rubber sheet 23 has a small hole punched therein. When the cell is assembled, steel rod I0 projects through these apertures and the yielding nature of rubber sheet 23 permits matic gas valve. Due to this construction, however, the rubber prevents entrance of carbon dioxide or moisture into the cell from the atmos phere. Instead of discs 22 and 23 the can I8 may be sealed in some cases by pouring a layer of y Gilsonite pitch into the top of the Figure 2a shows a preferred form of cell construction and shows the cells embodied in a battery. IIn this construction containers 80 of the individual cells are molded tubes of rubber hydrochloride or Plioflm closed at one end. 'I'he roll of electrodes and spacers prepared as shown' in Figure 1 is rst dried at 100 C. and then impregnated with the electrolyte at C., a vacuum being applied for about 2 minutes to facilitate impregnation and removal of gases. The electrolyte is then allowed to cool and the roll removed while the electrolyte is still uid, the excess is wiped oi and the roll inserted in Pliolm container 80. Zinc tab I6 is made longer in Can.

pregnated roll has been inserted. in container,

a disc Il of rubber vhydrochloride is placed over the exposed end and a layer l2 of-lhard inert petroleum wax-such as 'Superlawax having' a` Another type of multi-ceu battery een be made as shown in Figure 'I by placing a stack of cells A" .5I in a cardboard tube 1l, 4providing pressed metal terminal bosses 12 in cardboard end discs 1I, nlling anyfree vspace in the tube with wax Il and turning in the ends of the tube to maintain con- -Y tact pressure between the parts.

. The peculiar applicability of the solid crystallfl() melting point of about/170er. or Gilsonite pitch is poured on top to seal the top end4 of the container. The wax adheres strongly to the Plioiilr'n walls effectively sealing the container. When cool the cellmay be quickly dipped in molten Superline potassium hydroxide electrolyte for dry primary cellsfespecially as j compared with other 'crystalline alkalinel electrolytes,v will be evident @from the following: In measurements made onj cells of the structure shown in Fig. 1 with an lawax to form a thin wax coating vover` the entire Any numberof such cells maybe connected in series by removing the'protective film from portions of the terminals andsoldering thezinc tab il of one cell t the center steel rod I o'f the next cell,.and so forth. e A `simple battery of desired voltagecan be made/by placing the required number of cells, al1 connected in series, side by side, in an open-topped cardboard'or sheet metal box or tray 84 and pouring a layer 83 of wax over them to cover them and leave only the end' terminals exposed.

Figure 3 shows'a modied electrode assembly wherein a plain strip of zinc Ifoil Slis used and electrode areaof 8 sq. in. and under a meter load `of 300 ohms, the voltages obtained with different :electrolytes Vat C. wereas follows:.

' with zoo gm. xorrand 10o m1. water E=1.c mit With' 360 gm. KOH and 100 ml. Water E=.98 volt With 200 gm. NaOH and 100 ml. water E=.05 .volt

2OWith 360 gm. NaOH and 100 ml. water E=less With'zool gms. KOH per 10o m1, or water=a2 is spaced from coated steel electrode Il by nylon cloth layers 3| placed against the zinc electrode and regenerated sheet cellulose layers 32 in contact withthe coated steel electrode'.

In this case spacing of the threads in the cloth provides 35 the necessary free space into which the regenerated cellulose sheet mayrexpand as4 it swells when it absorbs electrolyte. Other cloth layers, .suchV l as `glass cloth and other materials resistant to the electrolyte, may, in some cases, be substituted for the nylons y n Figures 4 to 7 show the construction and asthan .01 volt When aload is applied the voltage of the NaOH cells drops to practically zero.' v

I have found that the specific resistivity at 20 C. of the KOH electrolyte is also considerably lower than the` NaOH at 20 C. as is indicated from the following; a cell was- 'ohms per cm.s e With 360 gms. KOH per 100 ml. of water-1400 l ohms per cin.s 'A .f

iWith 200 gms. NaOH per.100 ml., of water=421 ohms per cm"V With 360 Igms.V NaOH per 100 3.03 X l0 ohms per cm3*- In the lowest range, the resistivity of the KOH should exceed 25ohms per cm.a at 20 C.

sembiy of disctype cells embodying features of i l the invention. One such cell, asshown inFig ures 4 and 5, is made up of a zinc disc lil, a steel discfll having a coating 42 of cuprlc oxide coin-` position prepared and applied as previously -described, on one face thereof, two glycerine-free regenerated sheet cellulose discs 43 impregnated with the alkaline electrolyte of the previously described composition, and a sealing ring,r M. Ring M may ,be made of an'impervious sheet material such as Plioiilm or other sealing material not readily attacked Yby the electrolyte.

The cell may be made by first cementing. the Plioillm washer l! to the copper oxide compound surface of the steel disc, then soaking the regen--V erated cellulose discs in a solution of 290 grams Crystalline lithium hydroxide electrolytes have a still higher resistance. The specific resistance values will vary to some degree with therate of cooling. 4The above values were obtained under conditions similar to those encountered in the cells. The resistance values given are those of the crystallizedeiectrolytes outside of the cell and without the addition of otherl materials.

'It is noteworthy that there is almost no difference in resistivity between liquid electrolytes of the prior art having NaOH and KOH respectively as the active ingredients. A 25% solution KOH andl00 milliliters of water at.1'00 C.1for

5 minutes', removing and rolling olf-the excess electrolyte with a rubber roller, placing two such discs 43 inthe central recess formed by Washer Il, then applying a ring 45 of vinyl chloride cement to the zincvdisc and pressing it on top of thepre-assembly with the vinyl chloride cement against thePlioiilmd The assembly is then put in a press which 'is kept at 60 C. until the .cement has dried and bonded the assembly together to forma completed cell 50.

Several of such`cells may be stacked together. as shown in Figure 6 to form asbatteryof Ahigher voltage. A rubber band 80 is suiiicient to hold them together. Terminals' suchv as .metal discs il having wires 62' soldered to them may be placed at the ends of the stack.

of either NaOH or KOH has a resistivity in the Y order of 4 ohms per cm.3

Concentrations of potassium hydroxide above 175 grams C. P. KOH per 100 ml. of -water will solidify when cooled to room temperature. 'I'hese might in some cases be used but-to obtain the optimum of shelf life it is essential that the melt- "ing point of the crystalline electrolyte exceed thel maximum ambient temperature that the cell is expected to encounter.

1 this should exceed 25 C.,`but should preferably be higher, and for tropical use it should be much higher, 'for example above 55 C.

The most practical range of concentrations for the crystalline electrolyte is formed as described above by, using between 200 and 400 gms. C. P. potassium hydroxide, yielding compositions containing between 57 and 70% KOH. For normal commercial use 300 grams is preferably used, giving a 65% composition. For tropical use 360 grams may be used, yielding a 68% composition.

Due to the close spacing of the electrodes and the short electrolytic current' path of large area The resistivity measured in I ml. of water:

For non-tropical use thus provided. Ithis cell has a comparatively low internal resistance at ordinary temperatures and good current capacity. The cell has an open circuit voltage of about 1 volt. Two such cells connected in 4series and having an electrolyte containing 290 grams of potassium hydroxide to 100 milliliters of water, and having a zinc elec as 5% or less, or sulfur compound (for example,l

ammonium polysulde) to the hydroxide prior to the addition of water so as to form an alkali metal sulfide component in the electrolyte increases the open circuit voltage to 1.2 volts in the case of potassium hydroxide. The shelf life at elevated temperatures, however, is not so long. The addition, in small amounts, of other sulfur group elements, such as selenium, has a similar eiect. The internal resistance of the cell may be reduced and the voltage output may also be raised by using a composite spacer comprising pure porous cotton paper, such as Dexter B A in combination with the regenerated cellulose sheet. Alternate layers may be used. A similar result may be accomplished by the addition of 5% to 20% bentonite to the electrolyte.

While cupric oxide is the prefered depolarizer for highest current capacity, other depolarizers may in some cases be substituted, such as the sulfldes of copper, lead sulfide or oxide and the like. Cadmium can be used in place of zinc for the other electrode although it produces a cell of lower voltage and therefore is not so desirable.

Sodium and lithium `hydroxides have somel limited utility for crystalline electrolytes either singly or in mixtures with potassium hydroxide. Sodium hydroxide solutions containing above 120 grams of C. P. sodium hydroxide (having around 13% water) to 100 ml. of water will solidify when cooled. Compositions having`150 grams produce excessive shelf attack on the electrodes and on the cellulose spacer. This can be reduced by using an alkali resistant zinc alloy or composition.

While specic embodiments of the invention have been described it is intended to cover the invention broadly within the extent and scope of the appended claims.

What is claimed is:

1. The method of making a unitary spacer electrolyte member for dry primary cells which comprises heating a concentrated alkali metal hydroxide electrolyte containing water of hydration and which is normally solid at 25 C. to a temperature at which said electrolyte is iluid and immersing and holding regenerated sheet cellulose therein until said sheet becomes impregnated with said electrolyte.

2. The methodl ofy making a dry cell which comprises winding two electrodes in enrolled form with a regenerated cellulose sheet spacer member therebetween, at least one of said electrodes being corrugated or otherwise deformed so as to allow said cellulose sheet to expand, immersing said wound structures in a concentrated alkali metal hydroxide electrolyte containing water of hydration and which is normally solid at 25 C. but which has -been heated to a temperature at which it hasbecome fluid, and holding said structure in said electrolyte until the cellulose sheet has become adequately impregnated' therewith.

3. The method of making an electrode for primary cells which comprises coating a metal. foil with a mixture of finely divided cupric oxide and micionized graphite suspended in a liquid organic alkali-resisting binder solutionv containing 4a solvent and baking said coated foil at a temperature below the decomposition temperature of said binder until the solvent is driven off and untilthe coating is bonded to said foil.

4. The method of making a unitary spacerelectrolyte member for dry primary cells which comprises heating a concentrated potassium hy droxide solution which is normally solid at 25 C. to a temperature at which said solution is fluid and immersing and holding regenerated sheet cellulosetherein until said sheet becomes impregnated with said solution.

5. The method of making a dry cell which comprises winding' an electrode sheet formed of a metal selected from the group consisting of zinc and cadmium and a depolarizer electrode sheet into enrolled form with absorbent sheet spacers therebetween, immersing the w'ound structure in a concentrated potassium hydroxide solution which is normally solid at 25 C. while said solution is at a temperature at which said solution is fluid, and holding said structure in said solution until it has become impregnated, and then allowing said structure to cool to solidify said solution.

6. 'lhe method of making a dry cell which comprises winding an electrode sheet formed ofA a metal selected from the group consisting of zinc and cadmium and a depolarizer electrode sheet into enrolled form with absorbent sheet spacers therebetween, at least one of said electrodes being corrugated or otherwisedeformed so as to allow saidy spacers to expand, immersing the wound structure in a concentrated potassium hydroxide solution which is normally solid at 25 C. while said solution is at a temperature at which said solution is fluid, and holding said structure in said solution until it has become impregnated and then allowing said structure to cool to solidify said solution.

SAMUEL RUBEN.

REFERENCES CITED The following references are of record in the iile of this patent:

UNITED STATES PATENTS Number Name Date 405,196 Barrett June 11, 1889 555,304 Crowdus Feb. 25, 1896 856,162 Kitsee June 4, 1907 1,045,822 Dodge Dec. 3, 1912 1,162,449 Burgess Nov. 30, 1915 1,259,485 Byrne Mar. 19,1918 1,282,057 Erwin Oct. 22, 1918 1,510,617 Vare Oct. 7, 1924 1,744,302 Engle et al Jan. 21, 1930 1,835,867 Heise Dec. 8, 1931 1,863,791 Heise June 21, 1932 1,891,206 Ruben Dec. 13, 1932 1,920,151 Ruben July 25, 1933 2,062,543 Waterman Dec. 1, 1936 2,078,772 Pitt Apr. 27, 1937 2,231,320 Burgess Feb. 11, 1941 2,275,281 Berl Mar. 3, 1942 FOREIGN PATENTS Number Country Date 6,664 Great Britain 1911 399,561

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